Pilaster form for an insulating concrete form building system

ABSTRACT

An insulated concrete wall is constructed by assembling main forms in rows where each main form has two panels of insulating foam and a series of bridging members extending between the panels for holding the panels apart for receiving a cast concrete layer therebetween. The top and bottom surfaces have mating projections and recesses to hold the forms interconnected. A pilaster form is provided for use with the main forms in defining a pilaster column extending from the concrete structural wall on at least one side of the wall, the pilaster form comprising a generally channel shape in plan for attachment to the main forms vertically along a slot in one of the panels of the main forms to define a web portion arranged to lie generally parallel to the panel and two leg portions arranged such that the leg portions extend from the web portion toward said one of the panels to hold the web portion at a position spaced from said one of the panels for receiving a column of the cast concrete within the pilaster form and connected to the cast concrete layer.

This invention relates to a pilaster form shaped and arranged for use with an insulating concrete form building system in which a series of forms are stacked with each form defined by two panels of foam defining a central channel into which concrete is poured to create a wall in which the structure is defined by the concrete layer and the insulation is provided by the inner and outer panels of foam.

BACKGROUND OF THE INVENTION

A construction system for building insulated concrete walls is well-known and widely used and becoming significantly more popular. This includes two panels of insulating foam which are connected by injection molded bridging members which have ends arranged so that one end is buried within one foam panel and the other end buried in the other foam panel to hold the panels parallel and spaced. These blocks are commonly of the order of 4 feet in length 18 inches in height and are provided with meshing projections and recesses on the top and bottom surfaces so that the forms can be assembled in rows each on top of the next. This arrangement provides a channel between the two panels which can be filled with concrete. The bridging members include suitable shaping arrangements to receive and hold conventional reinforcing bars.

Walls of this type are therefore formed simply and with minimal labour with the insulation already in place so that the structure may be finished simply by suitable cladding on the inside and outside surface.

In some cases, particularly when the wall construction is of greater height which is common used in a commercial building, it is desirable to provide a pilaster column integral with the wall structure where there are series of such pilaster columns at spaced positions along the length of a wall structure. These are provided for increased structural strength as is well known and commonly used in the industry. Conventionally a pilaster column is formed by providing from work on each side of the concrete wall at the required location so as to provide a column of increased width at the required location for the pilaster column. Thus when the concrete is poured the wall is formed simultaneously with the shaped pilaster column as an integral structure.

One example of forms of this type is shown in the literature of the present assignee under the trademark “Logix lcf”. This literature shows examples of forms of the above general type.

However up till now there has been no effective way to form pilasters with the insulating forms of the above type. No form nor system appears to be currently available in a system of this type which allows the pilaster to be conveniently and effectively formed as part of the system.

In literature obtained from the internet by a manufacture of forms of this type which is Reddiform is shown a type of form known as a “pilaster form”. However the technique by which this is used to form pilasters is not clear and it not made clear in the literature.

SUMMARY OF THE INVENTION

It is one object of the invention to provide an improved apparatus of this type for forming pilaster columns with the concrete wall structure.

According to one aspect of the invention there is provided an apparatus for use in constructing an insulated concrete wall comprising:

a plurality of main forms for assembling in stacked rows of side by side forms;

each main form comprising:

two panels of insulating foam each having a top surface, a bottom surface, two end surfaces, an inner surface facing toward the other of the panels and an outer surface facing away from the other of the panels;

a plurality of bridging members extending between the panels for holding the panels at a spaced position defining a channel between the inner surfaces of the panels for receiving a cast concrete layer therebetween;

the top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next row of forms to hold the forms interconnected;

the main forms being shaped and arranged such that the layer of concrete can be cast in the space between the panels of the stacked rows of forms to define a concrete structural wall insulated on each side by the panels;

and a pilaster form for use with the main forms in defining a pilaster extending from the concrete structural wall on at least one side of the wall, the pilaster form comprising:

a pilaster form body defined from insulating foam to define a generally channel shape in plan for attachment to the main forms vertically along one of the panels of the main forms along a slot in said one of the panels of the main forms;

the pilaster form body having a web portion arranged to lie generally parallel to said one of the panels and two leg portions arranged such that the leg portions extend from the web portion toward said one of the panels to hold the web portion at a position spaced from said one of the panels for receiving a column of the cast concrete within the pilaster form and connected to the cast concrete layer.

Preferably the pilaster form body has a height equal to the height of the main forms such that the pilaster form body has top and bottom surfaces co-planar with the top and bottom surfaces of the main forms when installed such that the pilaster forms can be assembled in a common row with the main forms.

Preferably the leg portions lie at right angles to the web portion to form a rectangular or square pilaster column. However other shapes are possible such as polygonal or circular.

Preferably an inner surface of the pilaster form body has a series of recesses to tie to the concrete column which may comprise longitudinal grooves on the web portion and the leg portions.

Preferably the pilaster form body includes a buried strip member extending along the pilaster form body substantially along the full height of the pilaster form body.

Preferably the buried strip member lies substantially parallel to an outer surface of the pilaster form body for receiving fastening screws or the like.

Preferably the buried strip member includes two portions at right angles such that one portion lies parallel to an outer surface of the leg portion and one portion lies parallel to the web portion.

Preferably the pilaster form body includes longitudinally extending markings defining a length to be cut off of the leg portions so as to reduce the distance of the web portion from said one of the panels.

Preferably the pilaster form body has top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next form to hold the forms interconnected.

According to a second aspect of the invention there is provided a method for constructing an insulated concrete wall comprising:

providing a plurality of main forms;

each main form comprising:

two panels of insulating foam each having a top surface, a bottom surface, two end surfaces, an inner surface facing toward the other of the panels and an outer surface facing away from the other of the panels;

a plurality of bridging members extending between the panels for holding the panels at a spaced position defining a channel between the inner surfaces of the panels for receiving a cast concrete layer therebetween;

the top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next row of forms to hold the forms interconnected;

the main forms being shaped and arranged such that the layer of concrete can be cast in the space between the panels of the stacked rows of forms to define a concrete structural wall insulated on each side by the panels;

providing a pilaster form for use with the main forms in defining a pilaster extending from the concrete structural wall on at least one side of the wall, the pilaster form comprising:

a pilaster form body defined from insulating foam to define a generally channel shape in plan for attachment to the main forms vertically along one of the panels of the main forms along a slot in said one of the panels of the main forms;

the pilaster form body having a web portion arranged to lie generally parallel to said one of the panels and two leg portions arranged such that the leg portions extend from the web portion toward said one of the panels to hold the web portion at a position spaced from said one of the panels for receiving a column of the cast concrete within the pilaster form and connected to the cast concrete layer;

assembling the main forms in rows to define a continuous channel between the panels thereof with one panel of the forms on one side of the channel and the other panel of the forms on the other side of the forms;

forming a vertical slot in the panels on at least one side of the channel;

attaching the pilaster forms such that they are attached to said at least one side at the slot with the web portion spaced from the channel and the leg portions extending to panels on said at least one side such that the pilaster forms define a column inside the web portion and connected to the channel;

filling the channel and the column with concrete to form a pilaster column on the concrete wall;

and leaving the pilaster form body in place covering the pilaster column as an insulating layer.

BRIEF DESCRIPTION OF THE DRAWINGS

One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:

FIG. 1 is a top plan view of the pilaster form itself separate from the main forms and the assembled structure.

FIG. 2 is a top plan view of the pilaster form of FIG. 1 attached to a wall structure formed by the conventional main forms.

FIGS. 3 and 4 show alternative techniques for assembling the pilaster form of FIG. 1 in the wall structure.

FIG. 5 is an isometric view of a portion of a wall structure with the pilaster column assembled with the concrete wall in an insulated structure.

In the drawings like characters of reference indicate corresponding parts in the different figures.

DETAILED DESCRIPTION

In FIG. 5 is shown a concrete wall structure including a central layer 10 of concrete which is coated on one side by a fist panel 11 of an insulating foam material and on the other side by a second panel 12 also of similar insulation foam material. The wall structure is formed with integral concrete layer created between a series of forms generally indicated at 13. Each form 13 as shown in FIG. 2 comprises one foam panel 11A and a second foam panel 12A held in spaced positions by a plurality of injection moulded bridging members 15. The bridging members are arranged at spaced positions along the length of the form. Each bridging member has a pair of web plates generally at right angles to the plane of the bridging member so that the web plates are parallel to the surfaces of the foam panels. One of the web plats is located in the plane of the inside surface of the respective panel. The other web plate is spaced outwardly and is buried within the foam panel. In this way the bridging members locked into the foam panel so that the foam panels are held at a predestined space position. In addition the web plates buried within the foam panels act as fastening plates into which screw fasteners can be applied for attaching the cladding.

As shown in FIG. 5, the forms are assembled in rows side by side so that in FIG. 5 three rows 16, 17 and 18 are shown for each row being created by a series of the forms end to end. The forms of one row are longitudinally offset relative to the forms of the next row so that the junctions between the forms are offset. The forms each include in the top and bottom surfaces of the panels a series of projections and recesses which mesh when the forms are placed on top of the next. The shape and arrangement of the meshing projection and recesses can vary of different types as well known to one skilled in the art. The effect is that the forms are held against longitudinal transverse movement when placed in the rows by the projections with the projections being sufficient to maintain the structure integral until the reinforcing bars are placed within the rows and the concrete poured. Once the concrete is poured and set, the structure is held integral by the concrete layer itself with the foam panels butting each other to provide a complete inserting layer on both surfaces of the concrete wall.

The system provides, according to the present invention, a pilaster form generally indicated at 20 and shown independently in FIG. 1. The pilaster form comprises a generally channel shape member defining a body of foam with a web portion 21 and two legs 22 and 23 at right angles to the web portion. The thickness of the leg portion and the web portions is equal and is generally approximately equal to the thickness of the foam panels in the conventional main forms.

Thus the leg portions have an outside surface 24 and an inside surface 25 where those surfaces are parallel and spaced by the thickness of the foam material. The web portion also has an outside surface 26 and an inside surface 27 again spaced by the thickness of the foam material. The web portion connects to the leg portions at a right angle and is integrally formed therewith as an integral foam structure.

Buried within the form at the junctions between the web portion and the leg portion is provided a pair of furring strips indicated at 28 and 29. These furring strips are arranged to extend substantially on the full height of the pilaster form. The height as shown in FIG. 5 of each pilaster form is substantially equal to the height of the main forms. In this way each row of main forms can be laid and a cooperating pilaster form applied and held in place as discussed hereinafter.

The inside surface of the leg portions includes a series of longitudinally extending ribs and recesses 30 at a position adjacent the web portion. Similarly the inside surface 27 of the web portion includes ribs and recesses arranged in a transversely spaced array as indicated at 31. These grooves or ribs act to engage into the surface of the concrete when poured into the pilaster form so as to provide a keying effect with the concrete surface to hold the foam insulating layer defined by the pilaster form in place after the casting is complete and the concrete set.

The pilaster from has markings 32 on the leg portions parallel to the web portion so as to define a position at which the leg portion can be cut to reduce the length of the leg portion away from the web portion. It will be appreciated that the length of the leg portion varies the spacing of the web portion from the outside surface of the main form when attached so that this changes the dimensions of the pilaster column cast within the pilaster form. The markings 32 are provided at suitable positions for conventionally dimensioned pilaster columns.

In assembling the pilaster form with the main forms as shown in FIGS. 2, 3 and 4, the main form is cut at a position indicated at 40 and 41 to define a slot 42. This slot is located at a position spaced from a bridging member 15 or the bridging member 15 can be cut also if required depending upon the dimensions of the slot cut. As shown in FIGS. 2, 3, and 4, the slot can be cut in only one of the panels so that the intention is the pilaster only be defined on only one side of the layered concrete when cast.

In FIG. 5 a slot 42 is cut in one panel 11 and a second slot 42A is cut in the other panel 12 so that a pilaster column can be defined on both sides of the central layer 10.

In FIGS. 2, 3 and 4, the width of the slot is equal to the intended width of the pilaster column. In this way, the pilaster form is attached onto the outside surface of the existing foam panel 11A. As shown at the top of FIG. 5, it is also possible to cut the slot 41A so that the end edges 40 and 41 are outside the leg portions 22 and 23 so that the leg portions insert into the slot. For this purpose of course the leg portions must be longer than when butted on the outside as shown in FIGS. 2, 3 and 4. It is preferred for more effective assembly that the slots be alternated wider and narrower with alternating pilaster forms of shorter and longer legs in each of the rows 16, 17 and 18. This provides an improved intermeshing of the foam pieces of the panels and the leg portions of the pilaster forms.

As shown in FIGS. 2, 3 and 4, suitable form work is applied onto the outside surface of the pilaster form to hold the pilaster form in place during the casting of the pilaster column. In FIG. 2 this form work comprises an outer plate 50 and two pieces plumber 51 and 52. These are fastened together with nails 53 and bridging fasteners 54 can be applied through the whole structure from the outside of the pilaster form through to the opposite panel 12A and a panel 55 applied on that panel. This therefore transfers loads through the structure so that forces on the pilaster form tending to push it away from the panel 11A are resisted by the forces from the plate 55 against the panel 12A.

In FIG. 3 is shown an alternative arraignment in which additional transverse tying members 56 are provided between the lumber pieces 51 and 52.

In the arrangement of FIG. 4, additional plates 57 and 58 are provided on either side of the pilaster from which are fastened to narrower lumber pieces 51A and 52A again to provide improved holding forces. In this arrangement the transverse member 56 can be omitted.

Thus in the assembly of the system, the pilaster forms are selected and cut to the required dimensions so that they fit into or on the outside of the slots 42 as described above. The slots 42 are then formed in the panels, either one of the panels or in both of the panels as required. The slots are preferably formed out the position spaced from the ends of the forms. With the pilaster forms in place and interconnected each from the top of one to the bottom of the next by the intermeshing projections 60, the form work is applied to hold the pilaster forms in place during the casting of the pilaster column and the layer of concrete between the forms.

Suitable reinforcing bars are laid in place as is known to one skilled in the art within the space between the main forms and also into the columns within the pilaster form. These reinforcing bars can include horizontal bars and also vertical bars along the length of the column.

With the form work in place holding the pilaster form attached to the main form, the concrete can be poured into place thus integrally forming the concrete wall and the pilaster column. Once the concrete is set, the form work can be removed leaving the pilaster form in place so that the concrete and the pilaster column is covered on both the outer surface and the inner surface by the foam layer.

Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. 

1. Apparatus for use in constructing an insulated concrete wall comprising: a plurality of main forms for assembling in stacked rows of side by side forms; each main form comprising: two panels of insulating foam each having a top surface, a bottom surface, two end surfaces, an inner surface facing toward the other of the panels and an outer surface facing away from the other of the panels; a plurality of bridging members extending between the panels for holding the panels at a spaced position defining a channel between the inner surfaces of the panels for receiving a cast concrete layer therebetween; the top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next row of forms to hold the forms interconnected; the main forms being shaped and arranged such that the layer of concrete can be cast in the space between the panels of the stacked rows of forms to define a concrete structural wall insulated on each side by the panels; and a pilaster form for use with the main forms in defining a pilaster extending from the concrete structural wall on at least one side of the wall, the pilaster form comprising: a pilaster form body defined from insulating foam to define a generally channel shape in plan for attachment to the main forms vertically along one of the panels of the main forms along a slot in said one of the panels of the main forms; the pilaster form body having a web portion arranged to lie generally parallel to said one of the panels and two leg portions arranged such that the leg portions extend from the web portion toward said one of the panels to hold the web portion at a position spaced from said one of the panels for receiving a column of the cast concrete within the pilaster form and connected to the cast concrete layer.
 2. The apparatus according to claim 1 wherein the pilaster form body has a height equal to the height of the main forms such that the pilaster form body has top and bottom surfaces co-planar with the top and bottom surfaces of the main forms when installed.
 3. The apparatus according to claim 1 wherein the leg portions lie at right angles to the web portion
 4. The apparatus according to claim 1 wherein an inner surface of the pilaster form body has a series of recesses to tie to the concrete column.
 5. The apparatus according to claim 4 wherein the series of recesses comprise longitudinal grooves on the web portion and the leg portions.
 6. The apparatus according to claim 1 wherein the pilaster form body includes a buried strip member extending along the pilaster form body substantially along the full height of the pilaster form body.
 7. The apparatus according to claim 6 wherein the buried strip member lies substantially parallel to an outer surface of the pilaster form body.
 8. The apparatus according to claim 6 wherein the buried strip member includes two portions at right angles such that one portion lies parallel to an outer surface of the leg portion and one portion lies parallel to the web portion.
 9. The apparatus according to Cclaim 1 wherein the pilaster form body includes longitudinally extending markings defining a length to be cut off of the leg portions so as to reduce the distance of the web portion from said one of the panels.
 10. The apparatus according to claim 1 wherein the pilaster form body has top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next form to hold the forms interconnected.
 11. A method for constructing an insulated concrete wall comprising: providing a plurality of main forms; each main form comprising: two panels of insulating foam each having a top surface, a bottom surface, two end surfaces, an inner surface facing toward the other of the panels and an outer surface facing away from the other of the panels; a plurality of bridging members extending between the panels for holding the panels at a spaced position defining a channel between the inner surfaces of the panels for receiving a cast concrete layer therebetween; the top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next row of forms to hold the forms interconnected; the main forms being shaped and arranged such that the layer of concrete can be cast in the space between the panels of the stacked rows of forms to define a concrete structural wall insulated on each side by the panels; providing a pilaster form for use with the main forms in defining a pilaster extending from the concrete structural wall on at least one side of the wall, the pilaster form comprising: a pilaster form body defined from insulating foam to define a generally channel shape in plan for attachment to the main forms vertically along one of the panels of the main forms along a slot in said one of the panels of the main forms; the pilaster form body having a web portion arranged to lie generally parallel to said one of the panels and two leg portions arranged such that the leg portions extend from the web portion toward said one of the panels to hold the web portion at a position spaced from said one of the panels for receiving a column of the cast concrete within the pilaster form and connected to the cast concrete layer; assembling the main forms in rows to define a continuous channel between the panels thereof with one panel of the forms on one side of the channel and the other panel of the forms on the other side of the forms; forming a vertical slot in the panels on at least one side of the channel; attaching the pilaster forms such that they are attached to said at least one side at the slot with the web portion spaced from the channel and the leg portions extending to panels on said at least one side such that the pilaster forms define a column inside the web portion and connected to the channel; filling the channel and the column with concrete to form a pilaster column on the concrete wall; and leaving the pilaster form body in place covering the pilaster column as an insulating layer.
 12. The method according to claim 11 wherein the pilaster form body has a height equal to the height of the main forms such that the pilaster form body has top and bottom surfaces co-planar with the top and bottom surfaces of the main forms when installed.
 13. The method according to claim 11 wherein the leg portions lie at right angles to the web portion
 14. The method according to claim 11 wherein an inner surface of the pilaster form body has a series of recesses to tie to the concrete column.
 15. The method according to Caim 14 wherein the series of recesses comprise longitudinal grooves on the web portion and the leg portions.
 16. The method according to claim 1 wherein the pilaster form body includes a buried strip member extending along the pilaster form body substantially along the full height of the pilaster form body.
 17. The method according to claim 16 wherein the buried strip member lies substantially parallel to an outer surface of the pilaster form body.
 18. The method according to claim 16 wherein the buried strip member includes two portions at right angles such that one portion lies parallel to an outer surface of the leg portion and one portion lies parallel to the web portion.
 19. The method according to claim 11 wherein the pilaster form body includes longitudinally extending markings defining a length to be cut off of the leg portions so as to reduce the distance of the web portion from said one of the panels.
 20. The method according to claim 11 wherein the pilaster form body has top and bottom surface having mating projections and recesses thereon by which the bottom surface of one form can intermesh with the top surface of a next form to hold the forms interconnected 